CA1124554A - Method of producing hardfaced plate by welding deposition - Google Patents
Method of producing hardfaced plate by welding depositionInfo
- Publication number
- CA1124554A CA1124554A CA336,487A CA336487A CA1124554A CA 1124554 A CA1124554 A CA 1124554A CA 336487 A CA336487 A CA 336487A CA 1124554 A CA1124554 A CA 1124554A
- Authority
- CA
- Canada
- Prior art keywords
- plate
- welding
- cylindrical
- supporting surface
- cylindrical supporting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
- B23K9/044—Built-up welding on three-dimensional surfaces
- B23K9/046—Built-up welding on three-dimensional surfaces on surfaces of revolution
- B23K9/048—Built-up welding on three-dimensional surfaces on surfaces of revolution on cylindrical surfaces
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4998—Combined manufacture including applying or shaping of fluent material
- Y10T29/49982—Coating
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
- Arc Welding In General (AREA)
- Structures Of Non-Positive Displacement Pumps (AREA)
- Rigid Containers With Two Or More Constituent Elements (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
Disclosed are methods of producing hardfaced plate which eliminates distortion while making weld deposits along the length of a sheet-like plate of relatively ductile and weldable material by securing the plate about a cylindrical supporting surface, then welding hardfacing material to the plate's surface which causes the plate to shrink against and be supported by the cylindrical surface which effectively maintains the plate against substantial distortion during the welding. The plate with the welded hard-facing material is then removed from the cylindrical surface. Pre-ferably, the composition of the hardfacing material is such as to form random cracks at a frequency of not less than about one in each three inches upon cooling from the welding temperature, and preferably of the order of about 5/8" to about 3/4". Preferably, the cylindrical surface, which may be a portion of a drum, is rotated about a horizontal axis while welding one or more weld beads along the circumferential length of the plate and for ease of operation at the top of the plate's surface. The methods are particularly suited for making hardfaced plate in which the plate is not over 1/2" in thickness, for example 1/4" and 3/8"
thickness plate.
Disclosed are methods of producing hardfaced plate which eliminates distortion while making weld deposits along the length of a sheet-like plate of relatively ductile and weldable material by securing the plate about a cylindrical supporting surface, then welding hardfacing material to the plate's surface which causes the plate to shrink against and be supported by the cylindrical surface which effectively maintains the plate against substantial distortion during the welding. The plate with the welded hard-facing material is then removed from the cylindrical surface. Pre-ferably, the composition of the hardfacing material is such as to form random cracks at a frequency of not less than about one in each three inches upon cooling from the welding temperature, and preferably of the order of about 5/8" to about 3/4". Preferably, the cylindrical surface, which may be a portion of a drum, is rotated about a horizontal axis while welding one or more weld beads along the circumferential length of the plate and for ease of operation at the top of the plate's surface. The methods are particularly suited for making hardfaced plate in which the plate is not over 1/2" in thickness, for example 1/4" and 3/8"
thickness plate.
Description
Background of the Invention The conventional method of producing hardfaced plate, as described in my U.S. Patent No. 3,494~749, with bulk welding as described in that Patent and my United States Patent Nos.
3,076,888 and 3,060,307 has been to strap down a plate and try to hold it from distorting while ma~ing the weld deposits with one or two beads along the length of the plate. When the deposit is made on 1/2" or thicker plate, the plate remains reasonably flat and the deposit can be made in a reasonably uni-form manner. However, the great majority of this hardfaced plate is used in fan blades where weight is a major problemO
When these thicknesses are clad in the flat position, the heat of welding combined with the shrinkage of the weld coating on cooling causes a buckling of the plate with undesirable effects that effect the quality of the deposit, and in most cases, the ability to clad the plate with more than one bead at a time.
When the plate'buckles toward the weld nozzle, the dis-tance from the weld zone on the plate to the welding nozzle is changed. The buckle is such that the distance of the welding wire (called "s~ickout") is decreased which calls for a greater amount of current in the weld operation to melt the welding wire since it must be heated from ambient to melting, while the wire is traveling a relatively short distance from the welding nozzle to the weld zone. This greater current will cause undesirable penetration into the plate and dilute the overlay with iron from the plate.
. .
~ - 2 - ~
s~
If the buckle is away from the nozzle the welding operation requires less current because the longer distance which the welding wire ~ravels from the welding nozzle to the work causes it to heat to melting with less rate of heat input because of the longer time of heating~ This lowex than normal current will result i~ in-~0 -2a -. ., . ~
1 sufficient melting of the base plate and loss of bond for the facing and will often cause incomplete melting of the granular hardfacing materials resulting in a "lean" alloy.
In addition, the buckling causes the plate to be unlevel and the deposit applied will tend to flow away from the weld ~one and form a non-uniform, non-level overlay layer of too-heavy or too-light thic~ness.
The use of multlple welding heads serves to compound the problem and results in limiting the number of weld heads to one or two depending on the thickness of the plate to be clad. Also, in the cladding of thinner plate, such as 1/4", the plate heats through and tends to melt too easily in the weld zone giving unwanted dilution of the deposit with iron from the pla-te.
Additionally, the flat plate method gives a low per-centage of total welding time in the cladding or hardfacing operation because after welding only one or two beads the length of the plate, the operation must be stopped, the weld bead or beads cleaned and the plate or the heads returned to the starting end and repositioned before the welding can again be started. The total time to clad a plate is thus increased by between 50 and 100%, depending on the efficiency of cleaning, returning to start, and repositioning the weld heads depositing the beads.
It would be highly advantageous to provide methods of overlaying or hardfacing plate which eliminate all of the foregoing difficulties.
Summary of the Invention The present invention is directed to methods of overlaying or hardfacing plate which ellminates all of the foregoing difficulties. More specifically, the present invention is directed to methods which eliminate the foregoing difficulties by the manner of holding and controlling the plate 1 while being overlayed or hardfaced.
In short, the plate to be clad or hardfaced is seeured about a cylindrical supporting surface, such as a drum, pre-freably the plate ends being welded together to f~rm a cylin-der and the cylindrical plate is sllpped over the cylindrical surface of the drum. ~lardfacing is then deposited on the plate surface preferably on its upper surface as the drum and the plate are being rotated about a horizontal axis. As the welding progresses, the cylindrical plate being clad shrinks clrcumferentially and becomes tight against the cylindrical surface of the drum which maintains the plate in a rigid cylindrical shape and allows the welding "stickout" to be maintained at an aceurate constant value~
The drum also dissipates the welding heat and prevents a thin plate from being overheated and excessively melted to dilute the overlay alloy.
Any desired welding head can be utilized and, preferably, upon completion of 360 degrees o~ welding, the head or heads are moved automatically to start new weld beads continuous with the laid down weld beads so that the welding operation proceeds without stop until the entire cylinder is clad.
After the welding or cladding operation, and the plate has cooled, it is easily removed from the cylindrieal surface o~ the drum, the ends are cut, and the plate is very easy to flatten from any residual cylindrieal eurvature left in the plate.
The "reverse" eurvature present in the eylinder form counters the dishing tendaney, that is the clad side tendin~ to eurve so as to be concave with the clad side up, and permits the finished produet to be nearly flat when the eylinder is eut.
For many uses, the flattening operation ean be eliminated as the product can be sold as commercially flat as produced; however, because of the residual tension in the claddin~, ~he plate is ~;LZ~.~S~
, very easy to flatten rom any residual cylindrical curvature left in the plate as it comes off the cladding operation.
The i~vention will now be described further by way of example only and with reference to the accompanying drawings;
wherein;
Figure 1 is a Eragmentary side view illustrating buckling up effects of prior art plate cladding or hardfacing methods.
Figure 2 is a view similar to that of Figure 1 illustrat-ing buckling down effects of prior art plate cladding or hardfacing methods.
Figure 3 is a perspective view illustrating pla-te to be clad or hardfaced ormed in a cylinder with its opposed ends welded together.
Figure 4 is a side elevational view illustrating the c~lindrically-formed plate of Figure 4 disposed over the outer cylindrical surface of a drum.
Figure 5 is a front view o~ Figure ~.
Figure 6 illustrates the laying down of welding beads during the stepover operation.
Figure 7 is an end view of clad or hardfaced plate illustrating the shape of the plate clad without restrai~t according to prior art methods.
Figuxe 8 ls a view similar to that of Figure 7 illustrat-ing the shape of the plate on the cylinder before cladding.
E'igure 9 is a view similar to that of Fiyures 7 and 8 illustratiny the shape o the plate afte~ cladding in cylin~
drical orm and the ends being cut apart.
Description of the Preerred Embodiments Referring now to Figure 4, a plate 10 to be clad or hard surfaced is formed into a cylinder lOa as shown by brlnginy ~;-.
1 the ends 12 and 14 opposite to one another and then welding them together. To reduce the curvature of the plate 10 in the cylinder, the length of the plate to be used is preferably above 20 feet, typically 30 or 40 feet for ease o~ handling. A 30-foot plate would result in a cylinder diameter of 9.55 feet.
As previously mentioned, the base plate 10 may be formed of any relatively ductile, malleable and weldable material, such as the mild steels and the like, and which may be cut, bent, and shaped, as desired. While any thickness of plate can be hard-surfaced according to the present inven~ion, the methods of thepresent invention are particularly advantageous for use in plates having a thickness of 1/2" and under, for example in the 1/4"
and 3/8" thicknesses such as used for fan blades where weight is a major problem.
Referring now to Figures 4 and 5, the cylindrically-shaped plate lOa is slipped over the cylindrical supporting surface 16 of the drum 18, which drum 18 is formed of heavier plate typically 1/2" and above, for example 3/4" thickness and which is con-structed so as to be slightly smaller in diameter than that of the plate cylinder lOa to be clad. The cylindrical supporting surface 16 is constructed to e~tend axially beyond the sides 20 of the plate cylinder lOa to accomodate the power rollers 22 which are driven by any suitable source of power, not shown. The guide rolls 24 are provided so as to bear aga:inst each side 23 of the drum 18 to prevent the drum Erom walking as it turns on the rolls 22.
The power turning rolls 22 and guide rolls 24 may be of any desired type and shape, which are available upon the market, and, accor~ingly, no detailed description is deemed necessary or given.
"~ ~
1 The frum 18 may be formed of an~ suitable material which will withstand the conditions of use/ such as steel, and which is strong enough to support the plate 10 ln a relatively even cylin-drically surface upon shrinkage against the cylindrical supporting surface 16 as welding of the overlay or hardfacing particles pro-ceeds. Preferably, the material forming the cylinarical supporting surface should be able to conduct heat away from the cylindrical plate 10a.
As the drum 18 is being rotated, welding of the overlay of hardfacing particles is performed preferably by laying down a bead 26 at the upper surface and adjacent one side of the cylindrical plate 10a. This welding is accomplished by the welding head or nozzle 28 having a consumable wire electrode 30 extending therethrough and with the deposition of bulk welding particles to the cylindrical plate 10a. Any type of welding head can be used and the welding can be either open arc or submerged or shielded arc as desired.
Suitable welding heads and methods which can be used for applying the welding bead and beads are thos illustrated and described in my U.S. Patents Nos. 3,076,888; 3,060,307; 3,172,991i 3,264,445;
20 3,260,834; 3,296,408; 3,513,287; 3,513,288; 3,513,283; 3,517,156;
3,609,292; 3,588,432; 3,735,087; 3,358,115. Any suitable method and apparatus for cladding or overlaying can be used.
The circumferential welding of the bead 26 on the outer surface of the cylindrical plake 10 is best illustrated in Fiyure 6, to which reference is now made. This can either be a single bead 32 or two or more beads as desired. As the drum 18 is ro-tated, the bead 26 is welded circumferentiailly to the cylindrical plate surface 10a. On the completion of the first 360, the welding head or heads 28 are moved axially across the cylinder to a position next to the laid down bead or beads 32 usually a distance of about 1 to 1/2" for one bead and a next bead 34 1 or beads laid down, then the welding head or heads 28 are moved again adjacent the just laid down bead 34 and the bead 36 or beads are then laid down. This continues until the desired amount of beads are laid down on the cylindrical plate lOa. The welding operator can thus proceed without stopping until the cylindrically-shaped plate lOa has its surface completely clad or hardfaced.
As previously mentioned, as the welding progresses, the cylindrical plate lOa shrinks circumferentially and becomes tight against the cylindrical supporting sur~ace 16 of the drum 18 which holds the plate in a rigid cylindrical shape and allows the welding stickout to be maintained at an accurate constant value. In addition, the contact with the cylindrical supporting surface 16 allows the welding heat to be dissipated and prevents a thin plate from being overheated and thus excessively melted which would dilute the overlay alloy with the metal o~ the base plate 10. It is unnecessary to lay down adjacent heads, but the heads can be spaced apart from one another and heads laid down in the spaces as desired.
The circumferentially-shaped plate 10 being overlaid is constantly in tension circumferentially. This ~rovides two desirable effects. First, it prevents upward buckling of the plate which would shorten stickout (distance from nozzle to work~
and cause non-uniform thickness and uneveness of deposit. Secondly, it encourages the formation of more frequent cracks which is the basis for the broad usefulness o the plate as a product, such as set forth in my U.S. Patent No. 3,~02,~59.
Because of the shrinkage present when the cladding cools from the molten to ambient the clad side 32 alsways tends to curve so as to be concave with the clad side up if the plate 10 is not restrained, such as illus-trated in Figure 7. The large diameter reverse curvature present in the cylinder form of the plate lOa, as illustrated in Figure 8, counters this dishing tendency and allows ,, ~
the finished product to be nearly flat when the cylinder lOa is removed from the drum 18 and the ends 12 and 14 are cut, such as illustrated in Figure 9. For many uses, this flattening opera-tion is eliminated and the product can be sold as commercially flat as produced. Because of the residual tension in the clad-ding, the plate lOa is very easy to flatten from any residual cylindrical curvature left in the plate as it comes off the cladding operation and the ends 12 and 14 are cut.
The shrinkage of the cylindrically-shaped plate lOa in hardface overlaying or cladding occurs as follows: As overlay-ing or cladding begins the plate is heated by the overlay opera-tion to an average temperature of approximately 400F while the overlay being deposited has a temperature of about 2300F. The plate lOa being restrained from concaving on the overlay side, in cooling from 400F to ambient tries to shrink back to its original sizeO Meanwhile, the overlay is cooling from about 2300F to ambient so it tries to shrink or contract more than the metal plate lOa because it is cooling from about 2300F
while the plate lOa is only cooling from about 330F. When re-strained, the harder, more brittle overlay cracks to relieve thestresses of this shrinking, however, not all of the stress is removed by these cracks, so the plate lOa comes under compression in an amount equal to the tension stress left in the facing which compresses it from its original length to some length slightly less than the origin~l length depending on how much tension stress is left in the facing, which is a function of how many cracks have been formed. If the strip were not re-strained, the strip will concave on top since it is not re-strained, there will be fewer cracks and the plate lOa will not contact as much in length.
The effect of buckling of unrestrained plate is best illustrated in Figures 1 and 2 to which reference is now made.
_ g _ ~2~
When the plate 10 buckles upwardly as illustrated in Figure 1, the distance from the weld zone on the plate to the contact nozzle 28 is changed (called stickout). The distance the con-sumable wire electrode 30 travels to the plate 10 is decreased which results in a great amount of current being called for in the weld operation to melt the consumable wire electrode since it must be heated from ambient to melting, while the wire elec-trode 30 is traveling the shorter distance from the contact nozzle 28 to the weld zone. This greater current causes un-desirable penetration into the plate 10 and a resultant dilutionof the overlay 26 with the iron or metal of the base plate 10.
If the buckle is away from the nozzle as illustrated in Figure 2 this causes the consumable wire electrode 30 to travel a greater distance or have a greater stickout from ~he nozzle 28 to the work or base plate 10 causing the wire electrode 30 to heat to melting with less rate of heat input because of the longer time of heating. This lower than normal current required results in insufficient melting of the base plate 10 and the loss of bond for the facing and often causes incomplete melting of the granular material resulting in a "lean" alloy.
In addition, the buckling causes the plate 10 to be un-level and the deposit applied would tend to flow away from the weld zone and form a non-uniform, non-level overlay layer of too-heavy or too~light thickness.
As previously mentioned, this buckling and all the attendant disadvantages are eliminated by the present methods of overlaying or cladding plate and particularly plates of a thickness of up to 1/2" in thickness which tend to buckle more than thicker plates.
Accordingly, the present invention is well-suited and adapted to obtain the objects and ends and has the advantages and features mentioned, as well as others inherent therein.
While presently preferred embodiments of the present invention have been given for the purpose of disclosure, changes may be made therein which are within ~he spirit of the invention as defined by the scope of the appended claims.
3,076,888 and 3,060,307 has been to strap down a plate and try to hold it from distorting while ma~ing the weld deposits with one or two beads along the length of the plate. When the deposit is made on 1/2" or thicker plate, the plate remains reasonably flat and the deposit can be made in a reasonably uni-form manner. However, the great majority of this hardfaced plate is used in fan blades where weight is a major problemO
When these thicknesses are clad in the flat position, the heat of welding combined with the shrinkage of the weld coating on cooling causes a buckling of the plate with undesirable effects that effect the quality of the deposit, and in most cases, the ability to clad the plate with more than one bead at a time.
When the plate'buckles toward the weld nozzle, the dis-tance from the weld zone on the plate to the welding nozzle is changed. The buckle is such that the distance of the welding wire (called "s~ickout") is decreased which calls for a greater amount of current in the weld operation to melt the welding wire since it must be heated from ambient to melting, while the wire is traveling a relatively short distance from the welding nozzle to the weld zone. This greater current will cause undesirable penetration into the plate and dilute the overlay with iron from the plate.
. .
~ - 2 - ~
s~
If the buckle is away from the nozzle the welding operation requires less current because the longer distance which the welding wire ~ravels from the welding nozzle to the work causes it to heat to melting with less rate of heat input because of the longer time of heating~ This lowex than normal current will result i~ in-~0 -2a -. ., . ~
1 sufficient melting of the base plate and loss of bond for the facing and will often cause incomplete melting of the granular hardfacing materials resulting in a "lean" alloy.
In addition, the buckling causes the plate to be unlevel and the deposit applied will tend to flow away from the weld ~one and form a non-uniform, non-level overlay layer of too-heavy or too-light thic~ness.
The use of multlple welding heads serves to compound the problem and results in limiting the number of weld heads to one or two depending on the thickness of the plate to be clad. Also, in the cladding of thinner plate, such as 1/4", the plate heats through and tends to melt too easily in the weld zone giving unwanted dilution of the deposit with iron from the pla-te.
Additionally, the flat plate method gives a low per-centage of total welding time in the cladding or hardfacing operation because after welding only one or two beads the length of the plate, the operation must be stopped, the weld bead or beads cleaned and the plate or the heads returned to the starting end and repositioned before the welding can again be started. The total time to clad a plate is thus increased by between 50 and 100%, depending on the efficiency of cleaning, returning to start, and repositioning the weld heads depositing the beads.
It would be highly advantageous to provide methods of overlaying or hardfacing plate which eliminate all of the foregoing difficulties.
Summary of the Invention The present invention is directed to methods of overlaying or hardfacing plate which ellminates all of the foregoing difficulties. More specifically, the present invention is directed to methods which eliminate the foregoing difficulties by the manner of holding and controlling the plate 1 while being overlayed or hardfaced.
In short, the plate to be clad or hardfaced is seeured about a cylindrical supporting surface, such as a drum, pre-freably the plate ends being welded together to f~rm a cylin-der and the cylindrical plate is sllpped over the cylindrical surface of the drum. ~lardfacing is then deposited on the plate surface preferably on its upper surface as the drum and the plate are being rotated about a horizontal axis. As the welding progresses, the cylindrical plate being clad shrinks clrcumferentially and becomes tight against the cylindrical surface of the drum which maintains the plate in a rigid cylindrical shape and allows the welding "stickout" to be maintained at an aceurate constant value~
The drum also dissipates the welding heat and prevents a thin plate from being overheated and excessively melted to dilute the overlay alloy.
Any desired welding head can be utilized and, preferably, upon completion of 360 degrees o~ welding, the head or heads are moved automatically to start new weld beads continuous with the laid down weld beads so that the welding operation proceeds without stop until the entire cylinder is clad.
After the welding or cladding operation, and the plate has cooled, it is easily removed from the cylindrieal surface o~ the drum, the ends are cut, and the plate is very easy to flatten from any residual cylindrieal eurvature left in the plate.
The "reverse" eurvature present in the eylinder form counters the dishing tendaney, that is the clad side tendin~ to eurve so as to be concave with the clad side up, and permits the finished produet to be nearly flat when the eylinder is eut.
For many uses, the flattening operation ean be eliminated as the product can be sold as commercially flat as produced; however, because of the residual tension in the claddin~, ~he plate is ~;LZ~.~S~
, very easy to flatten rom any residual cylindrical curvature left in the plate as it comes off the cladding operation.
The i~vention will now be described further by way of example only and with reference to the accompanying drawings;
wherein;
Figure 1 is a Eragmentary side view illustrating buckling up effects of prior art plate cladding or hardfacing methods.
Figure 2 is a view similar to that of Figure 1 illustrat-ing buckling down effects of prior art plate cladding or hardfacing methods.
Figure 3 is a perspective view illustrating pla-te to be clad or hardfaced ormed in a cylinder with its opposed ends welded together.
Figure 4 is a side elevational view illustrating the c~lindrically-formed plate of Figure 4 disposed over the outer cylindrical surface of a drum.
Figure 5 is a front view o~ Figure ~.
Figure 6 illustrates the laying down of welding beads during the stepover operation.
Figure 7 is an end view of clad or hardfaced plate illustrating the shape of the plate clad without restrai~t according to prior art methods.
Figuxe 8 ls a view similar to that of Figure 7 illustrat-ing the shape of the plate on the cylinder before cladding.
E'igure 9 is a view similar to that of Fiyures 7 and 8 illustratiny the shape o the plate afte~ cladding in cylin~
drical orm and the ends being cut apart.
Description of the Preerred Embodiments Referring now to Figure 4, a plate 10 to be clad or hard surfaced is formed into a cylinder lOa as shown by brlnginy ~;-.
1 the ends 12 and 14 opposite to one another and then welding them together. To reduce the curvature of the plate 10 in the cylinder, the length of the plate to be used is preferably above 20 feet, typically 30 or 40 feet for ease o~ handling. A 30-foot plate would result in a cylinder diameter of 9.55 feet.
As previously mentioned, the base plate 10 may be formed of any relatively ductile, malleable and weldable material, such as the mild steels and the like, and which may be cut, bent, and shaped, as desired. While any thickness of plate can be hard-surfaced according to the present inven~ion, the methods of thepresent invention are particularly advantageous for use in plates having a thickness of 1/2" and under, for example in the 1/4"
and 3/8" thicknesses such as used for fan blades where weight is a major problem.
Referring now to Figures 4 and 5, the cylindrically-shaped plate lOa is slipped over the cylindrical supporting surface 16 of the drum 18, which drum 18 is formed of heavier plate typically 1/2" and above, for example 3/4" thickness and which is con-structed so as to be slightly smaller in diameter than that of the plate cylinder lOa to be clad. The cylindrical supporting surface 16 is constructed to e~tend axially beyond the sides 20 of the plate cylinder lOa to accomodate the power rollers 22 which are driven by any suitable source of power, not shown. The guide rolls 24 are provided so as to bear aga:inst each side 23 of the drum 18 to prevent the drum Erom walking as it turns on the rolls 22.
The power turning rolls 22 and guide rolls 24 may be of any desired type and shape, which are available upon the market, and, accor~ingly, no detailed description is deemed necessary or given.
"~ ~
1 The frum 18 may be formed of an~ suitable material which will withstand the conditions of use/ such as steel, and which is strong enough to support the plate 10 ln a relatively even cylin-drically surface upon shrinkage against the cylindrical supporting surface 16 as welding of the overlay or hardfacing particles pro-ceeds. Preferably, the material forming the cylinarical supporting surface should be able to conduct heat away from the cylindrical plate 10a.
As the drum 18 is being rotated, welding of the overlay of hardfacing particles is performed preferably by laying down a bead 26 at the upper surface and adjacent one side of the cylindrical plate 10a. This welding is accomplished by the welding head or nozzle 28 having a consumable wire electrode 30 extending therethrough and with the deposition of bulk welding particles to the cylindrical plate 10a. Any type of welding head can be used and the welding can be either open arc or submerged or shielded arc as desired.
Suitable welding heads and methods which can be used for applying the welding bead and beads are thos illustrated and described in my U.S. Patents Nos. 3,076,888; 3,060,307; 3,172,991i 3,264,445;
20 3,260,834; 3,296,408; 3,513,287; 3,513,288; 3,513,283; 3,517,156;
3,609,292; 3,588,432; 3,735,087; 3,358,115. Any suitable method and apparatus for cladding or overlaying can be used.
The circumferential welding of the bead 26 on the outer surface of the cylindrical plake 10 is best illustrated in Fiyure 6, to which reference is now made. This can either be a single bead 32 or two or more beads as desired. As the drum 18 is ro-tated, the bead 26 is welded circumferentiailly to the cylindrical plate surface 10a. On the completion of the first 360, the welding head or heads 28 are moved axially across the cylinder to a position next to the laid down bead or beads 32 usually a distance of about 1 to 1/2" for one bead and a next bead 34 1 or beads laid down, then the welding head or heads 28 are moved again adjacent the just laid down bead 34 and the bead 36 or beads are then laid down. This continues until the desired amount of beads are laid down on the cylindrical plate lOa. The welding operator can thus proceed without stopping until the cylindrically-shaped plate lOa has its surface completely clad or hardfaced.
As previously mentioned, as the welding progresses, the cylindrical plate lOa shrinks circumferentially and becomes tight against the cylindrical supporting sur~ace 16 of the drum 18 which holds the plate in a rigid cylindrical shape and allows the welding stickout to be maintained at an accurate constant value. In addition, the contact with the cylindrical supporting surface 16 allows the welding heat to be dissipated and prevents a thin plate from being overheated and thus excessively melted which would dilute the overlay alloy with the metal o~ the base plate 10. It is unnecessary to lay down adjacent heads, but the heads can be spaced apart from one another and heads laid down in the spaces as desired.
The circumferentially-shaped plate 10 being overlaid is constantly in tension circumferentially. This ~rovides two desirable effects. First, it prevents upward buckling of the plate which would shorten stickout (distance from nozzle to work~
and cause non-uniform thickness and uneveness of deposit. Secondly, it encourages the formation of more frequent cracks which is the basis for the broad usefulness o the plate as a product, such as set forth in my U.S. Patent No. 3,~02,~59.
Because of the shrinkage present when the cladding cools from the molten to ambient the clad side 32 alsways tends to curve so as to be concave with the clad side up if the plate 10 is not restrained, such as illus-trated in Figure 7. The large diameter reverse curvature present in the cylinder form of the plate lOa, as illustrated in Figure 8, counters this dishing tendency and allows ,, ~
the finished product to be nearly flat when the cylinder lOa is removed from the drum 18 and the ends 12 and 14 are cut, such as illustrated in Figure 9. For many uses, this flattening opera-tion is eliminated and the product can be sold as commercially flat as produced. Because of the residual tension in the clad-ding, the plate lOa is very easy to flatten from any residual cylindrical curvature left in the plate as it comes off the cladding operation and the ends 12 and 14 are cut.
The shrinkage of the cylindrically-shaped plate lOa in hardface overlaying or cladding occurs as follows: As overlay-ing or cladding begins the plate is heated by the overlay opera-tion to an average temperature of approximately 400F while the overlay being deposited has a temperature of about 2300F. The plate lOa being restrained from concaving on the overlay side, in cooling from 400F to ambient tries to shrink back to its original sizeO Meanwhile, the overlay is cooling from about 2300F to ambient so it tries to shrink or contract more than the metal plate lOa because it is cooling from about 2300F
while the plate lOa is only cooling from about 330F. When re-strained, the harder, more brittle overlay cracks to relieve thestresses of this shrinking, however, not all of the stress is removed by these cracks, so the plate lOa comes under compression in an amount equal to the tension stress left in the facing which compresses it from its original length to some length slightly less than the origin~l length depending on how much tension stress is left in the facing, which is a function of how many cracks have been formed. If the strip were not re-strained, the strip will concave on top since it is not re-strained, there will be fewer cracks and the plate lOa will not contact as much in length.
The effect of buckling of unrestrained plate is best illustrated in Figures 1 and 2 to which reference is now made.
_ g _ ~2~
When the plate 10 buckles upwardly as illustrated in Figure 1, the distance from the weld zone on the plate to the contact nozzle 28 is changed (called stickout). The distance the con-sumable wire electrode 30 travels to the plate 10 is decreased which results in a great amount of current being called for in the weld operation to melt the consumable wire electrode since it must be heated from ambient to melting, while the wire elec-trode 30 is traveling the shorter distance from the contact nozzle 28 to the weld zone. This greater current causes un-desirable penetration into the plate 10 and a resultant dilutionof the overlay 26 with the iron or metal of the base plate 10.
If the buckle is away from the nozzle as illustrated in Figure 2 this causes the consumable wire electrode 30 to travel a greater distance or have a greater stickout from ~he nozzle 28 to the work or base plate 10 causing the wire electrode 30 to heat to melting with less rate of heat input because of the longer time of heating. This lower than normal current required results in insufficient melting of the base plate 10 and the loss of bond for the facing and often causes incomplete melting of the granular material resulting in a "lean" alloy.
In addition, the buckling causes the plate 10 to be un-level and the deposit applied would tend to flow away from the weld zone and form a non-uniform, non-level overlay layer of too-heavy or too~light thickness.
As previously mentioned, this buckling and all the attendant disadvantages are eliminated by the present methods of overlaying or cladding plate and particularly plates of a thickness of up to 1/2" in thickness which tend to buckle more than thicker plates.
Accordingly, the present invention is well-suited and adapted to obtain the objects and ends and has the advantages and features mentioned, as well as others inherent therein.
While presently preferred embodiments of the present invention have been given for the purpose of disclosure, changes may be made therein which are within ~he spirit of the invention as defined by the scope of the appended claims.
Claims (7)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of producing hardfaced plate comprising, disposing a sheet-like plate of relatively ductile and weldable material and having a thickness of up to about 1/21" about a cylindrical supporting surface, then welding hardfacing material to the plate's surface, the distance between the plate and the cylindrical supporting surface being such that upon the welding of the hardfacing material to the plate surface, the plate is supported by the cylindrical supporting surface in a rigid cylindrical shape thereby avoiding substantial distortion of the plate during the welding and maintaining stickout at a substantially constant distance, the supporting surface dissipating welding heat effective to prevent the plate from being overheated and excessively melted to dilute the hardfacing material, and removing the plate from the cylindrical supporting surface after the welding of the hardfacing material to the plate's surface.
2. The method of claim 1 including, rotating the cylindrical supporting surface about a horizontal axis while welding the hardfacing material to the plate's surface.
3. The method of claim 1 or claim 2 where, the composition of the hard-facing material is such as to form cracks at a frequency of not less than about one in each three inches upon cooling from the welding temperature.
4. The method of claim 1 or claim 2 where, the composition of the hard-facing material is such as to form cracks in a frequency range of the order of about 5/8" to about 3/4".
5. The method of claim 1 or claim 2 where, the welding is by depositing welding beads generally circumferentially on the plate's surface.
6. The method of claim 1 or claim 2 where, the welding of the hard-facing material is at the top of the plate's surface.
7. The method of claim 1 or claim 2 where, the plate-like sheet is disposed about the cylindrical supporting surface by forming a cylinder of the plate of larger diameter than the cylindrical surface and welding the opposed ends of the plate together, and then placing the cylindrical sheet-like plate about the cylindrical supporting surface.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US05/946,677 US4237362A (en) | 1978-09-28 | 1978-09-28 | Method of producing hardfaced plate |
| US946,677 | 1978-09-28 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1124554A true CA1124554A (en) | 1982-06-01 |
Family
ID=25484799
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA336,487A Expired CA1124554A (en) | 1978-09-28 | 1979-09-27 | Method of producing hardfaced plate by welding deposition |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US4237362A (en) |
| CA (1) | CA1124554A (en) |
| DE (1) | DE2939538A1 (en) |
| FR (1) | FR2437265A1 (en) |
| GB (1) | GB2033282B (en) |
Families Citing this family (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2494153A1 (en) * | 1980-11-19 | 1982-05-21 | Creusot Loire | Deposition welding installation - with torch displacement control according to workpiece angular and longitudinal position |
| US4601322A (en) * | 1984-03-13 | 1986-07-22 | National Forge Company | Weld forming of pipe molds |
| US4557804A (en) * | 1984-05-18 | 1985-12-10 | Triten Corporation | Coke cooler |
| AU650974B2 (en) * | 1991-04-18 | 1994-07-07 | Gene Kostecki | Overlaying of plates |
| DE69223047T2 (en) * | 1991-04-18 | 1998-03-19 | Gene Noranda Kostecki | OVERLAPPING SHEETS |
| US6060678A (en) * | 1998-08-03 | 2000-05-09 | Arc Specialties | Gas shield strip clad welding system |
| US7361411B2 (en) * | 2003-04-21 | 2008-04-22 | Att Technology, Ltd. | Hardfacing alloy, methods, and products |
| US20090258250A1 (en) * | 2003-04-21 | 2009-10-15 | ATT Technology, Ltd. d/b/a Amco Technology Trust, Ltd. | Balanced Composition Hardfacing Alloy |
| US20070084556A1 (en) * | 2005-10-14 | 2007-04-19 | Langseder Neal E | Method of applying a label to a squeeze tube |
| US20070209839A1 (en) * | 2006-03-08 | 2007-09-13 | ATT Technology Trust, Ltd. d/b/a Arnco Technology Trust, Ltd. | System and method for reducing wear in drill pipe sections |
| US9976664B2 (en) | 2010-11-05 | 2018-05-22 | Hamilton Sundtrand Corporation | Furnace braze deposition of hardface coating on wear surface |
| US9816619B2 (en) | 2011-01-17 | 2017-11-14 | Hamilton Sundstrand Corporation | Thrust plate for butterfly valve |
| CN111360495B (en) * | 2020-04-11 | 2021-08-24 | 河南省煤科院耐磨技术有限公司 | Preparation method of ultrathin bimetal wear-resisting plate |
| JP7381422B2 (en) * | 2020-08-28 | 2023-11-15 | 株式会社神戸製鋼所 | Manufacturing method of modeled object and modeled object |
| CN114515887A (en) * | 2022-03-11 | 2022-05-20 | 郑州机械研究所有限公司 | Preparation method of low-dilution-rate surfacing wear-resistant plate |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3046936A (en) * | 1958-06-04 | 1962-07-31 | Nat Res Corp | Improvement in vacuum coating apparatus comprising an ion trap for the electron gun thereof |
| US3402459A (en) * | 1967-08-02 | 1968-09-24 | Roman F. Arnoldy | Method of making abrasion resistant plate |
| US3487489A (en) * | 1968-01-31 | 1970-01-06 | Kelley Co Inc | Tread plate |
| US3679858A (en) * | 1971-03-17 | 1972-07-25 | Detroit Flame Hardening Co | Method forming clad plates from curved surfaces |
-
1978
- 1978-09-28 US US05/946,677 patent/US4237362A/en not_active Expired - Lifetime
-
1979
- 1979-09-26 GB GB7933334A patent/GB2033282B/en not_active Expired
- 1979-09-27 FR FR7924024A patent/FR2437265A1/en active Granted
- 1979-09-27 CA CA336,487A patent/CA1124554A/en not_active Expired
- 1979-09-28 DE DE19792939538 patent/DE2939538A1/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| FR2437265B1 (en) | 1983-04-01 |
| GB2033282B (en) | 1982-08-25 |
| DE2939538C2 (en) | 1991-05-23 |
| DE2939538A1 (en) | 1980-04-17 |
| FR2437265A1 (en) | 1980-04-25 |
| GB2033282A (en) | 1980-05-21 |
| US4237362A (en) | 1980-12-02 |
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